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Sample Ductile Iron Pipe Specification
1. GENERAL
Ductile iron pipe (DIP) and fittings shall comply with ISO 2531, with
additional requirements as herein specified. The quality system of the pipe
manufacturer shall also be registered to an ISO 9000 quality standard by an
accredited registrar.
2. DUCTILE IRON PIPE
2.1 Push-on Joints:
Ductile iron socket and spigot pipes shall be Push-On Joint cast in nominal 6
meter lengths in accordance with ISO 2531. The socket shall be scientifically
designed with a unique gasket recess containing a dividing buttress, and the
joint shall be manufactured to such tolerances that the gasket is selfcentered, securely confined, and firmly compressed for a permanent, tight,
trouble free joint.
2.2 Restrained Joints:
Restrained joints shall be boltless restrained joints, utilizing Push-On Joint
sealing members.
2.3 Flanged Pipe:
Flanged pipe such as flange x spigot pipe, flange x flange pipe, socket x
flange pipe, shall be statically cast or fabricated from class K12 or heavier
wall thickness ductile iron in accordance with ISO 2531. Flanges shall be
screwed-on or integrally cast. Flanges shall be flat faced or raised face at the
manufacturer's option. Puddle flanges or wall collars for placement in
concrete walls shall be factory welded or integrally cast.
2.4 Testing:
DIP shall be tested in accordance with ISO 2531, with additional
requirements as herein specified.
2.5 Material:
Ductile iron (DI) used in the manufacture of pipe shall be in accordance with
ISO 2531, with additional requirements as herein specified.
2.6 Dimensional requirements
2.6.1 Outer diameter
The outer diameter of the spigot should comply with the following
tolerances:
100-300 mm diameter + 1.00 mm-1.50 mm
350-600 mm diameter + 1.00 mm-2.00 mm
700-1000 mm diameter + 1.00 mm-1.50 mm
1200-1600 mm diameter + 1.00 mm-2.50 mm
2.6.2 Tolerance on Masses
The tolerances on the standard masses are given in the table below.
Tolerance on Masses
Tolerance on standard mass
%
Type of casting
Pipes centrifugally
cast
Pipes not
centrifugally cast
Up to DN 200 inclusive
±8
Above DN 200
±5
±8
2.7 Markings:
Each pipe shall be marked per ISO 2531, with the following by labeling,
painting, cast-on or cold stamped marking, depending on the mark itself and
the product: (stenciling or marks on the outside of pipe shall be 25mm high
for 400mm and smaller; and 50mm high for 450mm and larger pipe sizes).
2.7.1 Size.
2.7.2 Class.
2.7.3 Weight
2.7.4 ISO 2531.
2.7.5 Length, if the pipe is not a nominal 6 meter length.
2.7.6 Gauged/Calibrated pipe shall have a green band painted behind the
bell indicating that the pipe is suitable for field cutting.
2.7.7 Manufacturer's name or trademark.
2.7.8 Year of manufacture.
2.7.9 Two circumferential lines on the spigot to provide a visual means of
checking that the spigot is properly inserted in the joint.
3. FITTINGS
3.1 Push-On Fittings:
Ductile iron socket fittings shall be Push-On Joint fittings manufactured in
accordance with ISO 2531. Bends and reducers shall be Class K12 and tees
shall be Class K14.
3.2 Restrained Joints:
Restrained joints shall be boltless restrained joints, utilizing Push-On Joint
sealing members.
3.3 Flanged Joints:
Flanged fittings shall be PN10, PN16, or PN25 with dimensions per ISO
7005-2. Flanges may be flat or raised faced at manufacturer's option. All
flanges on statically cast fittings shall be integrally cast.
3.4 Testing:
Each fitting shall be subjected to a factory air test of 1 bar in accordance
with ISO 2531.
3.5 Material:
DI used in the manufacture of fittings shall be in accordance with ISO 2531.
3.6 Markings:
Each fitting shall be marked per ISO 2531, with the following by labeling,
painting, cast-on or cold stamped marking, depending on the mark itself and
the product:
3.6.1 Size.
3.6.2 Type of bend: i.e., 1/4, 1/8, 1/16, 1/32.
3.6.3 ISO 2531.
3.6.4 Year of manufacture for fittings greater than 300mm.
3.6.5 Manufacturer's name or trademark.
3.7 WELDED-ON OUTLETS
3.7.1 Outlet Size and Parent Pipe Size:
Welded-on outlets shall be limited to branch outlets having a nominal
diameter not greater than 70% of the nominal diameter of the main line pipe
or 800mm whichever is smaller (see Table No. 1), with all fabrications
subject to further requirements of the following specification with regard to
design and manufacture. The MANUFACTURER shall have the capability to
furnish welded-on outlets as a radial (tee) outlet, tangential outlet, or lateral
outlet fabricated at a specific angle to the main line pipe (in 15° increments
between 45° and 90° from the axis of the main line pipe), as indicated on
the drawings.
Table No. 1
Main Line
Nominal Dia.
Max. Branch Outlet
Nominal Dia.
Main Line
Nominal Dia.
Max. Branch Outlet
Nominal Dia.
450mm
300mm
800mm
500mm
500mm
350mm
900mm
600mm
600mm
400mm
1000mm
800mm
700mm
500mm
1200mm
800mm
1400mm
800mm
1500mm
800mm
1600mm
800mm
3.7.2 Outlet Joint Types: The joints on welded-on branch outlets shall be
flexible joints meeting the requirements of ANSI/AWWA A21.11/C111 and
ISO 2531. When connections are not buried directly in the ground and
otherwise are not potentially subject to beam loads or misalignment in
service, flanged PN10, PN16 or PN25 outlet joints can be furnished.
3.7.3 Design and Testing:
3.7.3.1 The pipe wall thickness and weld reinforcement design for weldedon outlet fabrications shall provide a minimum safety factor of 2.5 for all
outlet offerings based on the yield strength of the pipe and deposited weld
material and while subjected to the maximum rated working pressure. The
Pressure Diameter Value (PDV), as defined by the following formula, shall be
6000 or less:
PDV = 0.562Pd2 / (Dsin2∆ ),
Where,
P = working pressure (in kg/cm2)
d = branch outside diameter (in mm)
D = main pipe outside diameter (mm)
∆ = branch diameter angle of deflection from the axis of the main pipe
3.7.3.2 The manufacturer shall confirm the design method with proof of
design hydrostatic tests of weakest outlet configurations. The
MANUFACTURER shall, at the request of the OWNER or OWNER’s ENGINEER,
provide representative proof test results confirming the design, hydrostatic
test results, and safety factors.
Reinforcing welds shall be placed using electrode material meeting
requirements of AWS A5.15 Class EniFe-CI or EniFeT3-CI . In addition,
electrode material shall be proven capable of producing a weld joint with a
Charpy V-notch impact strength of 13.5 J (when transverse impact
specimens are machined from butt-weld joined ductile iron pipe coupons)
when tested at 21° C + − 6° C. Carbon steel electrodes are not acceptable.
Upon request, the MANUFACTURER shall provide test results indicating
typical physical properties of the utilized weld material (an all-weld sample),
as well as typical physical properties from transverse tensile and impact
specimens machined from butt-weld joined ductile iron pipe coupons, to
show the suitability or equivalence of the electrodes used.
3.7.3.3 Parent pipe and branch outlet candidate pipe shall be centrifugally
cast ductile iron pipe manufactured in accordance with this standard.
Minimum classes for parent and outlet pipe shall be K12 per ISO 2531.
3.7.3.4 All welded-on outlet pipes shall be standard rated for a working
pressure of 16 kg/cm2. For any application involving working pressures in
excess of 16 kg/cm2, the manufacturer shall supply design information and
test results to the Owner or Owner's Engineer confirming the suitability of
the fabricated pipes for such applications.
3.7.3.5 Prior to the application of any coating or lining in the outlet area all
weldments for branch outlets to be supplied on this project shall be
subjected to an air pressure test of at least 1 bar. Air leakage is not
acceptable. Any leakage shall be detected by applying an appropriate
foaming solution to the entire exterior surface of the weldment and adjoining
pipe edges or by immersing the entire area in a vessel of water and visually
inspecting the weld surface for the presence of air bubbles. Any weldment
that shows any signs of leakage shall be repaired and re-tested in
accordance with the manufacturers' written procedures.
3.7.4 Quality Assurance
3.7.4.1 The manufacturer shall have a fully documented welding quality
assurance system and maintain resident quality assurance records based on
ANSI/AWS D11.2, the Guide for Welding Iron Castings or equal. The
manufacturer shall maintain appropriate welding procedure specification
(WPS), procedure qualification (PQR), and welder performance qualification
test (WPQR) records as well as appropriate air test logs documenting air
leakage tests on all welded on outlet pipes furnished to the project.
3.7.4.2 Prior to the start of manufacturing any proposed manufacturer not
meeting ISO 9001 or 9002 registration requirements shall submit to the
OWNER or OWNER's ENGINEER the name of an Independent Inspection
Agency and the agency’s qualifications. Submitted qualifications shall include
but are not limited to the following:
•
•
•
•
List of project references for projects of similar type and size
Resumes for inspection and testing personnel
Capacities for chemical and mechanical testing of material specimens
Frequencies for all instrument and testing equipment certifications
3.7.4.3 The independent inspection agency shall be responsible for all of the
following:
•
•
•
•
Verify compliance to written welding procedures, specification (WPS), and
procedure qualification (PQR).
Verify qualification of all welders (WPQR) per ANSI/AWS D11.2 criteria
Document use of Ni-Rod FC 55 cored wire or Ni-Rod 55 electrodes
manufactured by INCO Alloys, Stoody Cast-Weld 55-0 cored wire, or an
electrode with equivalent performance properties. The independent
testing agency shall provide test results indicating typical physical
properties of the utilized weld material (an all-weld sample), as well as
typical physical properties from transverse tensile and impact specimens
machined from butt-weld joined ductile iron pipe coupons to show the
suitability or equivalence of the electrodes used.
Witness and document all air testing of outlet welds
4. JOINT ACCESSORIES
4.1 Gaskets:
Push-On Joint gaskets shall be molded SBR rubber per ANSI/AWWA
C111/A21.11 and ISO 4633.
4.2 Flanged Joints Accessories:
4.2.1 Flange joint gaskets shall be 3mm nominal thickness, ring or full face
SBR rubber.
4.2.2 Bolts, nuts, and washers shall be galvanized steel.
4.3 Pipe Joint Lubricant for Push-On Joints:
Fastite lubricant shall be certified to the requirements of ANSI/NSF 61
standard for contact with potable water.
5. LININGS
5.1 Pipe:
5.1.1 General:
DIP shall be internally lined with sulphate resisting cement mortar lining in
accordance with ISO 4179, by a high speed, centrifugal process. The quality
system of the manufacturer shall be registered to an ISO 9000 quality
standard by an accredited registrar. Grinding of linings shall not be allowed.
The finished cement lining shall be uniformly smooth. In addition to
complying with ISO 4179, the linings shall also comply with the following
additional requirements.
5.1.2 Material:
The cement used shall be a sulphate resisting Portland Cement meeting the
requirements of ASTM C-150 Type II, ASTM C-150 Type V, and the chemical
requirements of BS 4027. Sand shall consist of inert, hard, strong, and
durable silica grains. The water used in the cement mortar shall be potable,
and free from injurious quantities of organic matter, alkali, salt or other
impurities that might reduce the strength, durability, or other desirable
qualities of the lining. All material in contact with water shall be certified to
meet the requirements of ANSI/NSF Standard 61.
5.1.3 Mortar:
The cement mortar shall contain not less than one part of cement to two
parts of sand, by volume.
5.1.4 Lining Thickness:
Cement lining thicknesses shall be per ISO 4179 and as shown in the table
below. For 450mm and larger pipe, the exposed edges of the lining shall be
essentially square and perpendicular with the axis of the pipe.
Nominal Lining
Thickness (mm)
Mean Minimum
Thickness (mm)
Minimum Value
at One Point
100mm - 300mm
3.0
2.5
1.5
350mm - 600mm
5.0
4.5
2.5
700mm - 1200mm
6.0
5.5
3.0
1400mm - 1600mm
9.0
8.0
4.0
Pipe Size
NOTE: For some service conditions, greater lining thicknesses may be
preferred. Consult the Manufacturer for specific recommendations.
5.1.5 Surface Preparation:
All surfaces to be mortar lined shall be cleaned as necessary to remove
foreign matter that could interfere with the adherence of the cement mortar
or protrude through the lining.
5.1.6 Lining Equipment and Process:
Linings shall be manufactured using centrifugal pipe rotational equipment
which sustains high-speed acceleration on the applied lining. The mortar of
the lining is cast centrifugally inside the pipe. Grinding of linings shall not be
allowed. The minimum centrifugal force for application of the lining shall be
45 G for 400mm and smaller and 60 G for 450mm and larger. Simultaneous
controlled vibration shall be applied to the pipe during high-speed rotation to
produce a lining of such high density and firm compaction that it will
immediately allow laitance washing with a large volume of water. The
manufacturer shall certify that the linings have been applied according to
these specifications. The mortar shall be mixed in batches. The amount of
cement and sand entering into each batch shall be measured by weight. The
quantity of mixing water entering into each batch shall be measured
automatically by an adjustable device, or it shall be otherwise measured to
ensure that the correct quantity of water is being added.
5.1.7 Washing and Finish:
After the mortar has been distributed, the rotational speed and vibration
shall be increased to produce a mortar lining with a uniformly smooth, firm
surface. Immediately after lining, the surface of the lining shall be washed
with water to remove excess laitance.
5.1.8 Curing:
Cement mortar linings shall be adequately cured in a facility with controlled
atmosphere. Linings shall be furnished standard without seal coat.
5.1.9 Cracks and Repairs:
Linings with cracks greater than 0.6mm in width are unacceptable. All
repairs of damage shall be reasonably smooth and may not project into the
waterway.
5.2 Fittings:
Fittings shall be internally lined with cement mortar lining composed of
similar quality cement, sand, and mixing water constituents as per pipe, and
lining thicknesses shall be equal to or greater than those for comparable size
pipe.
5.3 Flanged Pipes:
Flanged pipes shall be internally lined with a cement mortar lining composed
of similar quality cement, sand, and mixing water (see 5.1.2 (above)), and
lining thicknesses shall be equal to or greater than those for comparable
sizes of other pipes.
5.4 Seal Coat:
Seal coat may be supplied for cement mortar linings for pipe, flanged pipe,
and fittings, if necessary for special service conditions. Standard products
are furnished without seal coat in accordance with ISO 4179.
6. EXTERNAL COATINGS
6.1 Coating for DIP and Fittings:
Ductile Iron pipe and fittings shall be externally coated with a black
bituminous paint with a mean dry film thickness of not less than 70 microns
with a local minimum thickness of 50 microns. The coating shall be smooth,
neither brittle when cold nor sticky when exposed to the sun, and shall be
strongly adherent to the pipe.
6.2 Sockets and Spigots of DIP and Fittings:
All cement mortar lined ductile iron pipe and fittings shall have a coating of
black bituminous paint approximately 50 microns thick on the inside of
sockets and the outside of spigots.
7. ADDITIONAL EXTERNAL PROTECTION
7.1 Polyethylene Sleeves:
Polyethylene sleeves, if required, shall fully comply with ANSI/AWWA
C105/A21.5 and ASTM A674. The nominal thickness shall be 250 microns.
8. INSPECTION, TESTING, AND QUALITY
CONTROL
8.1 Standards:
Inspection and testing of products shall be carried out in accordance with the
following standards:
8.1.1 Ductile Iron Pipe and Fittings - ISO 2531.
8.1.2 Gaskets - SBR rubber per ANSI/AWWA C111/A21.11 for Push-On and
Mechanical Joints.
8.1.3 Linings - ISO 4179.
8.1.4 Coatings - ANSI/AWWA C151.A21.51
8.1.5 Polyethylene Sleeves - ANSI/AWWA C105/A21.5 and ASTM A674.
8.2 Material Tests:
8.2.1 Standard Mechanical Property Tests:
Mechanical tests will be performed for pipe and fitting manufacture in
accordance with ISO 2531, with additional requirements as herein specified.
8.2.2 Impact Testing:
In addition to standard mechanical testing requirements per ISO 2531, the
impact resistance of DIP furnished shall be confirmed by Charpy impact
testing full wall thickness samples machined from pipe produced for the
project. Impact sampling and testing shall be performed at least once every
hour. These samples shall be machined and tested in accordance with Sec.
51-12.2 of ANSI/AWWA C151/A21.51 and ASTM E23 as applicable, and the
minimum acceptance value for the test results corrected to a 10.2mm
(0.40") wall thickness shall be 9.5 Joules (7 ft-lb) for tests to be performed
at 21° ± 6° Celsius (70° ± 10° Fahrenheit). An additional low temperature
impact test shall be made from at least 10 percent of sample coupons taken
for the required 21° ± 6° Celsius (70° ± 10° Fahrenheit) impact tests. The
minimum acceptance value corrected to a 10.2mm (0.40") wall thickness for
these tests to be performed at -40° Celsius (-40° Fahrenheit) shall be 4.1
Joules (3 ft-lb).
8.3 Hydrostatic Tests for DIP:
Hydrostatic testing of pipe shall be performed in accordance with ISO
2531 at the internal test pressures given in the below table.
Work test pressure
DN
mm
Work test pressure
kg/cm2
Pipe centrifugally cast
K9
K7
100
50
-
150
50
-
200
50
-
250
50
-
300
50
-
350
50
-
400
50
-
450
80
-
500
76
-
600
70
55
700
60
51
800
60
49
900
60
47
1000
58
45
1200
40
40
1400
40
40
1500
40
40
1600
40
40
8.4 Fitting Tests:
One bar air tests of fittings shall be performed in accordance with ISO 2531.
8.5 Certifications and Records:
The manufacturer must supply a signed certificate stating that all DIP and
fittings fully comply with these specifications.
8.6 Visual Inspection and Dimensional Tests:
Pipes and fittings shall have adequate visual inspection of external coating
and internal lining surfaces and adequate measurements of wall thicknesses,
spigot outside diameters, socket inside diameters, and other product
dimensions to insure that the products furnished meet project specifications.
9. LININGS FOR SEWER SERVICE
9.1 Internal lining requirements for sewer service - pipe flowing full
(pH > 5.5)
Cement lining as shown in section 5 with seal-coat as shown in section 5.4.
Cement shall be sulfate resisting Type 5 per ASTM C150 or approved equal.
9.2 Internal lining requirements for sewer service - pipe not flowing
full with potential of generating acid on crown of the pipe (pH < 5.5)
9.2.1 Materials
9.2.1.1 Special Lining for Sewer Service
AMERICAN
can furnish 100mm – 1600mm (4"-64") PROTECTO 401 Ceramic
Epoxy-lined ductile iron pipe and fittings. This third-party designed and applied lining is amine cured with novalac and ceramic quartz pigment for an
approximately 1000 microns (40-mil) thick, high-build lining. For features
of and stipulations regarding assembly of pipes furnished with this
lining, users and installers of pipes with this lining should refer to the
website http://www.protecto401.com/.